Anisotropic bond magnet for four-magnetic-pole motor, motor using the same, device for orientation processing of anisotropic bond magnet for four-magnetic-pole motor

ABSTRACT

[Problem to be Solved]To realize an anisotropic bonded magnet that reduces cogging torque without lowering output torque. [Means for Solving the Problem]The present invention provides a hollow cylindrically shaped anisotropic bonded magnet for use in a 4-pole motor, formed by molding anisotropic rare-earth magnet powder with resin. The alignment distribution of the anisotropic rare-earth magnet powder in a cross section perpendicular to the axis of the anisotropic bonded magnet is in the normalized direction of the cylindrical side of the hollow cylindrical shape in the main region of a polar period, and in a transition region in which the direction of the magnetic pole changes, steadily points towards a direction tangential to the periphery of the cylindrical side at points closer to the neutral point of the magnetic pole, and becomes a direction tangential to the periphery of the cylindrical side at that neutral point, and steadily points toward the normalized direction of the cylindrical side at points farther away from the neutral point.

FIELD OF THE INVENTION

The present invention is related to a hollow cylindrical 4-poleanisotropic bonded magnet, a motor employing that magnet, and analignment process apparatus used to manufacture the hollow cylindrical4-pole anisotropic bonded magnet used in that motor.

BACKGROUND ART

Anisotropic bonded magnets molded in the shape of a hollow cylinder areknown as permanent magnets for use in motors. By molding this bondedmagnet in a state in which a predetermined magnetic field distributionis generated, an axis of easy magnetization for the magnet powder isaligned. For the orientation pattern in a cross-section perpendicular tothe axis of cylindrical bonded magnets, primarily, there is axialalignment, radial alignment, and polar alignment. Axial alignment is amethod in which in a cross section the magnet is magnetized in auniaxial direction, and radial alignment is a method in which the magnetis magnetized in a radial pattern emanating outward from thecross-sectional center, that is, in the normalized direction of thecircumference.

Also, anisotropic bonded magnets molded in the shape of a hollowcylinder are known as permanent magnets for use in motors. By moldingthis bonded magnet in a state in which a predetermined magnetic fielddistribution is generated, an axis of easy magnetization for the magnetpowder is aligned. For the orientation pattern in a cross-sectionperpendicular to the axis of cylindrical bonded magnets, primarily,there is axial alignment, radial alignment, and polar alignment. Axialalignment is a method in which the magnet is magnetized in a uniaxialdirection of a cross-section, and radial alignment is a method in whichthe magnet is magnetized in a radial pattern emanating outward from thecross-sectional center, that is, in the normalized direction of thecircumference.

SUMMARY OF THE INVENTION

[Problem the Invention Intends to Solve]

In recent years, there have been demands for drastic reductions in thesize and weight of motors. For example, there are axially aligned 2-polering magnets molded with a non-magnetic die, but because there is theproblem of low torque, these magnets can not answer the demands fordrastic reductions in the size and weight of motors. Also, there are2-pole ring magnets (for example, patent document 1 mentioned below)which, by embedding magnetic material in a non-magnetic die devised as adeveloped form of axial alignment, are formed of a 2-pole radiallyaligned part and a part thought to be axially aligned between themagnetic poles or of an unaligned isotropic part, but because these alsohave the problem of low torque, they can not answer the demands fordrastic reduction in size and weight of motors.

In recent years, in order to answer the demands for drastic reductionsin the size and weight of 1-300 W class DC brush motors, investigationshave been conducted of 4-pole motors using anisotropic bonded magnetswith more than 14 MGOe (for example, Japanese patent 3480733). 4-poleradially aligned magnets are assumed as the magnets used therein. Thethickness of the magnets used in these motors is 0.7 to 2.5 mm. In thiscase, the requirement of increased torque versus 2-pole motors can besatisfied, but there is the problem of high cogging torque. The reasonfor high cogging torque in this instance is that in the entire peripheryalignment is only in the radial direction, and when that magnet ismagnetized with 4 poles there is a sudden reduction in surface magneticflux density between the poles. In order to reduce cogging torque, it isnecessary to provide an aligning magnetic field and magnetizing magneticfield which gradually increases and decreases between the magnetic poles(the direction of the magnetic pole reverses in this part, and istherefore referred to below as the “transition region”) with changes inthe mechanical angle. When the internal magnetization in the transitionregion in distributed such that changes in the mechanical angle areaccompanied by gradual increases and decreases, it is possible toprevent the sudden reduction of surface magnetic flux density in thetransition region. Because the coercivity of this anisotropic bondedmagnet is high, an aligning magnetic field greater than 0.5 T isnecessary. However, it is difficult to provide a 0.5 T magnetic fieldfor a transition region in which the aligning magnetic field becomessmall with the above aligning methods.

So, for a 4-pole magnet used in a 4-pole motor, we extend a proceduredevised as a developed form axial alignment for a 2-pole magnet used ina 2-pole motor (patent document 1) to making the magnet and motor have4-poles. In a 4-pole motor, because the gap which can be used for thealigning yoke of the aligning die is small in comparison to that for2-pole alignment, there is the problem that it is difficult to provide asufficient aligning magnetic field in the transition region.

Incidentally, the material of the dice ring which is one part of the diewhich forms the outer peripheral surface of the bonded magnet isnon-magnetic material, and in order to improve the life span of the die,non-magnetic super-hardened material is frequently used. Even whenmerely making the dice ring of non-magnetic material and increasing thesupplied magnetic field, when fixing the size of the aligning die andapparatus, the maximum supplied magnetic field is determined by the sizeof the yoke, and a magnetic field greater than a particular value cannot be provided. Results of investigating adjustment of the distance inthe circumferential direction between yokes are as described below.

When attempting to increase the angle range of the region which isradially aligned, because the angular width between each yoke naturallyincreases, the distance in the circumferential direction between yokesof the magnetic body is too small, and short-circuiting of the magneticflux occurs between yoke poles. As a result, an effective magnetic fieldis not generated in the transition region of the cavity. Therefore, thesize of the aligning magnetic field in the transition region decreases.And, in order to reduce the magnetic field of the transition regionwhich leaks out of the cavity, that is, short-circuiting between theyoke poles, it is thought to keep the dice ring contacting the internalperipheral surface of the yoke at a distance in the radial direction andincrease the distance in the circumferential direction between the polesof each yoke. However, because the distance from the magnetic pole ofeach yoke to the cavity is increased, there is the problem that theradial alignment magnetic flux generated in the cavity is naturallyreduced. Also, when reducing the yoke angle width to avoid the leakage(short-circuiting) of magnetic flux between yoke poles, without recedingthe opposing surface of the yoke cavity in the radial direction, thearea of the aligned part in the region of the cavity which the aligningyoke faces is decreased, despite a sufficient aligning magnetic fieldbeing provided. Therefore, the aligning magnetic field of the transitionregion decreases due to the distance between yoke poles being too great,and in the bonded magnet unaligned isotropic dead space is generated inthe transition region. Torque therefore is reduced. Thus, it is notpossible to obtain magnet which satisfies high torque and low coggingtorque.

When a bonded magnet with this sort of alignment is used in, forexample, a 2-pole brush motor, the motor mainly shows the followingproperties. In a motor using a axially aligned bonded magnet, thesurface magnetic flux density in the normalized direction changessinusoidally with changes in mechanical angle, and therefore coggingtorque is low, but output torque is also low. On the other hand, in amotor using a radially aligned bonded magnet, the surface magnetic fluxdensity in the normalized direction changes squarely with changes inmechanical angle, and therefore both output torque and cogging torqueare high.

Patent document 1 below discloses a 2-pole magnet axially aligned in thetransition region between magnetic poles. However, in the case offorming a 4-pole bonded magnet, the actual angle between transitionregions is small as described above, and orientation in the transitionregions is actually difficult. So the idea of gradually changing thealignment direction of anisotropic rare earth magnet powder betweentransition regions is not disclosed, and this sort of alignment is notpossible using the described die structure.

Patent documents 2 and 3 below disclose bonded magnets having theproperty that, in the transition region between magnetic poles, thecomponents of the normalized direction of surface magnetic flux densityafter magnetization are gradually increase and decrease with changes inmechanical angle. However, even when this magnetization distribution isrealized, although cogging torque is reduced in comparison to the caseof radial alignment, motor output is small.

As shown in FIG. 11, according to patent documents 2 and 3, the die hasguides 51 a and 51 b, which are soft magnetic bodies, comprised of core52 which is a soft magnetic body, cavity 55, and ring 53 which is anon-magnetic body; and inserts 54 a and 54 b comprised of non-magneticbodies. In this molding die, ring 53 comprised of a non-magnetic body ofsuper-hard material is used in order to resist wear due to moldingpressure on the outside of cavity 55. Therefore, in transition region A,the magnetic path of the external normalized direction of cavity 55 isformed of ring 53 which is a non-magnetic body, and inserts 54 a and 54b which are non-magnetic bodies. Because these are all non-magneticbodies, in transition region A, a magnetic field distribution is notpossible in which the magnetic field distribution steadily pointstowards a direction tangential to the periphery of the cylindrical sideat points closer to the neutral point of the magnetic pole, and becomesa direction tangential to the periphery of the cylindrical side at thatneutral point, and steadily points toward the normalized direction ofthe cylindrical side at points farther away from the neutral point. Andin the case of using anisotropic rare-earth magnet powder, a largemagnetic field is necessary for alignment. Due to these things, inpatent documents 2 and 3, the aligning magnetic field components of thecircumferential direction in transition region A are not large, to theextent that alignment is sufficiently completed. Therefore, intransition region A, alignment is not complete, becoming isotopicalignment. This causes motor output to be less than in the case of usinga radially aligned anisotropic bonded magnet.

This time, recognizing the advantages of the molding die, aninvestigation of the alignment method was performed. In the aboveconventional technology, non-magnetic material is used for all parts ofthe magnet external diameter die for the transition region, andnon-magnetic super-hard material was frequently used with the objectiveof improving the lifespan of the die. Making non-magnetic material thematerial for the magnet external diameter die for the transition regionmeans that alignment can not be performed between cavity transitionregions.

When simply replacing the material of the magnet external diameter dieof the transition region with magnetic material such as iron which has acompletely opposite function, because it is thought that magnetic fluxflows through this magnetic member, it did not come to be used in theconventional technology.

So, as a result of thorough investigation, by making the magnet externaldiameter die between transition regions of magnetic material, andmoreover, using material with strength for the die material and makingit as thin as possible, magnetic saturation of this magnetic material isactively carried out, and in comparison to the case of usingnon-magnetic material, in the case of the same cavity, because it ispossible to simultaneously shorten air gaps in the magnetic circuit, itis possible to greatly improve the magnetic field supplied to the samecavity. As a result of that, in the transition region, it is possible toprovide an aligning field that gradually increases and decreases withchanges in mechanical angle.

Moreover, when magnetizing according to the same magnetization pattern,it is possible to distribute the internal magnetization betweentransition regions so that it gradually increases and decreases withchanges in mechanical angle, and the conventional dead space betweentransition regions can effectively be made to function. Therefore,because the surface magnetic flux density between transition regions isformed so as to gradually increase and decrease with changes inmechanical angle, it is possible to prevent a sudden drop in surfacemagnetic flux, and cogging torque can be greatly reduced whilepreserving cogging torque.

Thus, it is an object of the present invention to realize a small motorbonded magnet with high output torque and low cogging torque.

[Patent Document 1]

-   Japanese Unexamined Patent Application (Kokai) 6-86484    [Patent Document 2]-   Japanese Unexamined Patent Application (Kokai) 2004-23085    [Patent Document 3]-   Japanese Unexamined Patent Application (Kokai) 2004-56835

The structure of the invention for solving the problems described above,as cited in claim 1, is a 4-pole motor anisotropic bonded magnetcharacterized in that

the said magnet has a hollow cylindrical shape and a maximum energyproduct greater than 14 MGOe, formed by molding anisotropic rare-earthmagnet powder with resin, wherein

the alignment distribution of the anisotropic rare-earth magnet powderin a cross section perpendicular to the axis of the anisotropic bondedmagnet is in the normalized direction of the cylindrical side of thehollow cylindrical shape in the main region of a polar period, and in atransition region in which the direction of the magnetic pole changes,steadily points towards a direction tangential to the periphery of thecylindrical side at points closer to the neutral point of the magneticpole, and becomes a direction tangential to the periphery of thecylindrical side at that neutral point, and steadily points toward thenormalized direction of the cylindrical side at points farther away fromthe neutral point, and wherein

the 4-pole motor anisotropic bonded magnet in which the said alignmentdistribution is obtained is magnetized in an alignment direction.

The invention cited in claim 2 is a 4-pole motor anisotropic bondedmagnet according to claim 1, characterized in that orientation of theanisotropic rare-earth magnet powder between transition regions isperformed with an aligning magnetic field of greater that 0.5 T.

A magnetic field of greater than 0.5 T is necessary to sufficientlyalign anisotropic rare-earth magnet powder in resin. Particularly, ifthere is not magnetic field greater than 0.5 T in the case of Nd—Fe—Banisotropic magnet powder, which is difficult to align, 95% degree ofalignment can not be obtained. And, in the case of Nd—Fe—B anisotropicrare-earth magnet powder, a magnetic field greater than 0.70 T isnecessary to complete sufficient alignment of greater than 97%, and amagnetic field greater than 0.8 T is desirable. Accordingly, it isdesirable to make the magnetic field between transition regions in thecavity greater than 0.5 T. This degree of orientation was found from thepercentage of surface magnetic flux Br obtained when applying a 4.0 Tmagnetizing magnetic field after applying a particular aligning magneticfield relative to surface magnetic flux Br_(max) obtained when applyinga 4.0 T magnetizing magnetic field after applying a 1.5 T aligningmagnetic field to a work piece of the same shape. The location ofmeasurement for the aligning magnetic field in the cavity is theposition shown in FIG. 8 (stated later).

The invention cited in claim 3 is for the 4-pole motor anisotropicbonded magnet according to claim 1 or claim 2, characterized in that forthe surface magnetic flux density distribution in the normalizeddirection of the main polar period after magnetization of theanisotropic bonded magnet, the ratio of the difference between themaximum value and minimum value to the average value in this main regionis 0.2 or less.

The invention cited in claim 4 is for a motor having the 4-pole motoranisotropic bonded magnet according to any one of claims 1 through 3.

The anisotropic rare-earth bonded magnet of the present invention ismade according to the production process proposed by the applicant inJapanese Unexamined Patent Application (Kokai) p 2001-76917A,Registration Number 2816668. This magnet is manufactured, for example,by resin molding magnet powder comprised of Nd—Fe—B, and is stronglymagnetized in a uniaxial direction. This magnet is characterized in thatit has a maximum energy product (BHmax) that is more than four timesthat of conventional sintered ferrite magnets.

And, because this anisotropic rare-earth bonded magnet is formed byresin molding, it is easily and precisely formed. Thus, it is possibleto make the shape of the permanent magnet in the internal periphery ofthe motor case into a hollow cyclinder with good precision. That is, themagnetic field inside the motor due to the permanent magnet can be madeto have precise revolving symmetry. Because the symmetry of the internalmagnetic field has high precision, the electromagnetic revolving body inthe center can rotate receiving uniform torque. Thus noise due toconventional torque unevenness is reduced, making a quieter motorapparatus. Also, because the anisotropic rare-earth bonded magnet isresin molded in the shape of a hollow cylinder, it is easily installedinto the motor apparatus case. It is not necessary to install separate4-pole sintered ferrite magnets as in the conventional technology. Thatis, it has the advantage of a simplified production process.

The present invention has special characteristics in the distribution ofthe alignment direction (direction of the easily-magnetized axis afterrotating the anisotropic rare-earth magnet powder such that the easilymagnetized axis of the anisotropic rare-earth magnet powder direction ofthe aligning magnetic field is provided to the outside) of theanisotropic rare-earth magnet powder in a cross-section perpendicular tothe axis of the hollow cylindrical 4-pole anisotropic bonded magnet.That is, when expressing the periodic change of the magnetic poles asvariable of mechanical angle, in the region of mechanical angles whichchiefly contribute generation of torque, in the cross section, thealignment direction of the anisotropic rare-earth magnet powder is inthe normalized direction. And, in the transition region in which thedirection of the magnetic poles changes, as shown in FIG. 1, thealignment direction of anisotropic rare-earth magnet powder points in adirection tangential to the periphery of the cylindrical side atlocations gradually closer to the neutral point M of the magnetic poles,and points in a direction tangential to the periphery at that neutralpoint M, and points in the normalized direction of the cylindrical sideat locations gradually further from the neutral point M.

In the 4-pole anisotropic bonded magnet of the present invention, thealignment direction of the anisotropic rare-earth magnet powder is madeto have this kind of distribution, and moreover, the magnet ismagnetized in an alignment direction, obtaining a large magnetic moment.And, after this magnetization the surface magnetization vectors of the4-pole anisotropic bonded magnet resemble the alignment distribution,differing only in size. Also, it is desirable for the anisotropic bondedmagnet to have a maximum energy product of more than 14 MGOe. Morepreferably it will be greater than 17 MGOe. When the maximum energyproduct exceeds these values, it is possible to make great use of theadvantages of the alignment distribution of the present invention, andalong with effectively increasing motor output it is also possible toreduce cogging torque.

The structure of the invention cited in claim 5 for solving the abovementioned problems is an alignment processing apparatus comprising,

in an alignment processing apparatus for manufacturing, by molding usinga die, a hollow cylindrical-shaped anisotropic bonded magnet for use ina 4-pole motor, the magnet being formed by molding anisotropicrare-earth magnet powder with resin,

a core comprising a column-shaped magnetic body provided in a diemolding space;

a cavity of width 0.7 to 3 mm for filling with the anisotropic bondedmagnet raw material and molding the magnet, the cavity being formed in acylindrical shape on the outer periphery of the core;

No. 1 one dice, comprising of a magnetic body divided into quartersforming an aligning magnetic field in the normalized direction of thecavity, disposed on the outer periphery of the core and facing thecenter of the core;

No. 2 two dice divided into quarters, comprising a non-magnetic bodydisposed on the outer periphery of the core and facing the center of thecore, and, corresponding to the transition region in which the directionof the magnetic poles of the bonded magnet changes, located between theadjacent No. 1 dice;

coils conferring magnetic flux on the four No. 1 dice; and

a magnetic flux induction member comprising a thin-walled cylindricalmagnetic body which forms the outer peripheral surface of the cavity.

In the above mentioned core it is possible to use ferromagnetic softiron, such as pure iron and SS400; in the No. 1 dice it is possible touse ferromagnetic bodies such as pure iron and SS400; in the magneticflux induction member it is possible to use ferromagnetic bodies such asmagnetic cemented carbides, powder high-speed steel, and high-speedsteel material; and in the No. 2 dice it is possible to use non-magneticbodies such as SUS304 and precipitation hardening stainless steel.

The invention cited in claim 6 is the alignment process apparatusaccording to claim 5, characterized in that the thickness of themagnetic flux induction member is 1.0 to 3.5 mm.

The invention cited in claim 7 is the alignment process apparatusaccording to claim 5 or 6, characterized in that the magnetic fluxinducement member is comprised of super-hard material.

The invention cited in claim 8 is the alignment process apparatusaccording to any of claims 5 through 7, characterized in that thealigning magnetic field of the region of the cavity in which the No. 2dice are present induces magnetic flux greater than 0.5 T.

The invention cited in claim 9 is the alignment process apparatusaccording to any one of claims 5 through 8, characterized in that itpossesses a ring comprising cylindrical thin-wall magnetic super-hardmaterial which forms the inner surface of the cavity, disposed on theouter periphery of the core.

[Effect of the Invention]

The alignment distribution of the anisotropic rare-earth magnet powderis as shown in FIG. 1. The distribution of surface magnetization vectorsis as shown in FIG. 2. Because the alignment direction of anisotropicrare-earth magnet powder in the transition region is such that thealignment direction of anisotropic rare-earth magnet powder points in adirection tangential to the periphery of the cylindrical side atlocations gradually closer to the neutral point M of the magnetic poles,and points in a direction tangential to the periphery at that neutralpoint M, and points in the normalized direction of the cylindrical sideat locations gradually further from the neutral point M, when afterwardsmagnetizing, it is possible to increase the size of the magnetizationvectors in this transition region. As a result, motor output torque canbe increased the same as in the case of radial alignment, and it ispossible to decrease cogging torque in comparison to radial alignment.

And, a magnetic field in a normalized direction can be formed in thecavity by the No. 1 dice and core which are magnetic bodies divided intoquarters. In the transition region in which the direction of themagnetic poles changes, because the No. 2 dice, which are non-magneticbodies, are present, it is difficult to form a magnetic field in thenormalized direction. Because a cylindrical magnetic flux inductionmember comprising a magnetic body is provided which forms the outerperiphery of the cavity, a part of the magnetic flux induced in thenormalized direction of the cavity by the No. 1 dice located on bothsides of the No. 2 dice is also induced in the circumferential directionof the transition region. This magnetic flux induced in thecircumferential direction of the transition region leaks into thetransition region of the cavity. Therefore, in the transition region ofthe cavity, a magnetic field is generated possessing components of thecircumferential direction. The result of this is that in the transitionregion of the cavity, it is possible for the alignment direction ofanisotropic rare-earth magnet powder to point in a direction tangentialto the periphery of the cylindrical side at locations gradually closerto the neutral point of the magnetic poles, and to point in a directiontangential to the periphery at that neutral point, and to point in thenormalized direction of the cylindrical side at locations graduallyfurther from the neutral point. And, in the regions which mainlygenerate torque other than the transition region of the cavity, it ispossible to make the normalized direction be the alignment direction ofthe anisotropic rare-earth magnet powder.

When anisotropic rare-earth magnet powder is made into a bonded magnetand magnetized with this sort of semi-radial alignment, and used as a4-pole magnet in a motor, it will be a motor with high output and lowcogging torque. The manufacturing apparatus of the present invention caneasily manufacture a 4-pole anisotropic rare-earth bonded magnet havingthis sort of alignment.

SIMPLE EXPLANATION OF THE DRAWINGS

[FIG. 1]

A cross-sectional diagram showing the alignment distribution ofanisotropic rare-earth magnet powder in a bonded magnet having to dowith a specific embodiment of the present invention, and moreovermanufactured by an alignment process apparatus having to do with aspecific embodiment of the present invention.

[FIG. 2]

A properties diagram showing the relationship between the surfacemagnetic flux density of a bonded magnet having to do with the presentinvention and circumferential angle.

[FIG. 3]

A properties diagram showing the relationship between a semi-radiallyaligned bonded magnet having to do with an embodiment of the presentinvention and surface magnetic flux density in the normalized directionof a radially aligned bonded magnet, and between orientation andmagnetization vectors.

[FIG. 4]

A lateral cross-sectional diagram of the alignment processing apparatusof a bonded magnet having to do with an embodiment of the presentinvention.

[FIG. 5]

A vertical cross-sectional diagram of the alignment processing apparatusof a bonded magnet having to do with an embodiment of the presentinvention.

[FIG. 6]

A lateral cross-sectional diagram showing the detailed structure of theinside of the die of the same alignment processing apparatus.

[FIG. 7]

An explanatory diagram for explaining the alignment distribution havingto do with an embodiment of the present invention.

[FIG. 8]

An explanatory figure showing the measurement point of the aligningmagnetic field within the cavity in the die.

[FIG. 9]

A properties diagram showing the size properties of the aligningmagnetic field of the present invention, along with the alignmentproperties of a conventional example.

[FIG. 10]

A properties diagram showing the relationship between torque of a motorusing the bonded magnet of the present invention and revolutions, alongwith a conventional example.

[FIG. 11]

A cross-sectional diagram perpendicular to the axis of a bonded magnetof an alignment apparatus according to a conventional example.

PART NAMES

-   10 . . . anisotropic bonded magnet-   11 . . . axis-   12 . . . external wall-   30 . . . die-   32 . . . core-   34 . . . No. 1 ring-   35 . . . cavity-   36 . . . No. 2 ring-   38 a, 38 b, 38 c, 38 d . . . No. 1 dice-   40 a, 40 b, 40 c, 40 d . . . No. 2 dice-   44 a, 44 b, 44 c, 44 d . . . spaces-   46 a, 46 b, 46 c, 46 d . . . coils-   51 a, 51 b . . . guides-   55 . . . cavity

DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS

The present invention is explained below based on embodiments, but thepresent invention is in no way limited to the embodiments explainedbelow.

The anisotropic rare-earth bonded magnet is made according to theproduction process proposed by the applicant in Japanese UnexaminedPatent Application (Kokai) p 2001-76917A, Registration Number 2816668.This magnet is manufactured, for example, by resin molding magnet powdercomprised of Nd—Fe—B, and is strongly magnetized in a uniaxialdirection. This magnet is characterized in that it has a maximum energyproduct (BH_(max)) that is more than four times that of conventionalsintered ferrite magnets.

And, because this anisotropic rare-earth bonded magnet is formed byresin molding, it is easily and precisely formed. Thus, it is possibleto make the shape of the permanent magnet in the internal periphery ofthe motor case into a hollow cylinder with good precision. That is, themagnetic field inside the motor due to the permanent magnet can be madeto have precise revolving symmetry. Because the symmetry of the internalmagnetic field has high precision, the electromagnetic revolving body inthe center can rotate receiving uniform torque. Thus noise due toconventional torque unevenness is reduced, making a quieter motorapparatus. Also, because the anisotropic rare-earth bonded magnet isresin molded in the shape of a hollow cylinder, it is easily installedinto the motor apparatus case. It is not necessary to install separate4-pole sintered ferrite magnets as in the conventional technology. Thatis, it has the advantage of a simplified production process.

The present invention has special characteristics in the distribution ofthe alignment direction (direction of the easily-magnetized axis afterrotating the anisotropic rare-earth magnet powder such that the easilymagnetized axis of the anisotropic rare-earth magnet powder direction ofthe aligning magnetic field is provided to the outside) of theanisotropic rare-earth magnet powder in a cross-section perpendicular tothe axis of the hollow cylindrical 4-pole anisotropic bonded magnet.That is, when expressing the periodic change of the magnetic poles asvariable of mechanical angle, in the region of mechanical angles whichchiefly contribute generation of torque, in the cross section, thealignment direction of the anisotropic rare-earth magnet powder is inthe normalized direction. And, in the transition region in which thedirection of the magnetic poles changes, as shown in FIG. 1, thealignment direction of anisotropic rare-earth magnet powder points in adirection tangential to the periphery of the cylindrical side atlocations gradually closer to the neutral point M of the magnetic poles,and points in a direction tangential to the periphery at that neutralpoint M, and points in the normalized direction of the cylindrical sideat locations gradually further from the neutral point M.

In a 4-pole anisotropic bonded magnet in which the alignment directionof anisotropic rare-earth magnet powder is made to have this sort ofdistribution, by further magnetizing in the alignment direction, a4-pole anisotropic bonded magnet can be obtained which has a largemagnetic moment with a magnetization distribution the same as thealignment distribution. The distribution of surface magnetizationvectors in this 4-pole anisotropic bonded magnet after magnetization issimilar to the alignment distribution, differing only in size. Also, itis desirable for the anisotropic bonded magnet to have a maximum energyproduct of more than 14 MGOe. More preferably it will be greater than 17MGOe. When the maximum energy product exceeds these values, it ispossible to make great use of the advantages of the alignmentdistribution of the present invention, and along with effectivelyincreasing motor output it is also possible to reduce cogging torque.

Embodiment 1

FIG. 1 shows the structure of a bonded magnet having to do with aspecific embodiment of the present invention. In bonded magnet 10, byway of example, an Nd—Fe—B anisotropic rare-earth bonded magnet is used.Bonded magnet 10 has a hollow cylindrical shape including external wall12 formed around the periphery with axis 11 as the center. FIG. 1 is alateral cross-sectional diagram perpendicular to axis 11.

FIG. 1 shows the alignment direction of anisotropic rare-earth magnetpowder in exterior wall 12. Region B at a mechanical angle (actualrotation angle) of about 67.5 degrees is the region which primarilygenerates torque. And, region B at a mechanical angle of about 22.5degrees is the transition region in which magnetic poles change.However, the transition region means the region which is the provisionalmeasure of where magnetic pole direction begins to change from thenormalized direction to the direction tangent to the periphery, and thecomponents of the peripheral tangent do not critically exchange at thisborder. In region B, the anisotropic rare-earth magnet powder is alignedin the normalized direction of the cylindrical side. In transitionregion A, as shown in the figure, the alignment direction of theanisotropic rare-earth magnet powder gradually reverses with changesmechanical angle. That is, the alignment direction of anisotropicrare-earth magnet powder points in a direction tangential to theperiphery of the cylindrical side at locations gradually closer to theneutral point of the magnetic poles, and points in a directiontangential to the periphery at that neutral point M, and points in thenormalized direction of the cylindrical side at locations graduallyfurther from the neutral point M.

An aligning magnet field for orienting the magnet powder is applied, andafter press molding, the 4-pole anisotropic bonded magnet is magnetized.Shown in FIG. 2 are the properties for change in surface magnetic fluxdensity in the normalized direction after magnetizing in a range of amechanical angle of 90 degrees. As shown in FIG. 2, in region B, thesurface magnetic flux density in the normalized direction is roughlyfixed, and in transition region A the absolute value of surface magneticflux density in the normalized direction gradually increases anddecreases along with increases in mechanical angle θ.

Surface magnetic flux density of bonded magnet 10 in the normalizeddirection in the cross sectional diagram parallel to axis 11 is uniformalong the direction of axis 11. However, the magnet does not have to beuniformly magnetized along the direction of axis 11.

On the other hand, as a comparison example, a radially aligned bondedmagnet was produced. Dimensions are the same as the bonded magnet of theabove embodiment. Shown in FIG. 3 are the properties for change insurface magnetic flux density in the normalized direction of the bondedmagnet radially aligned and magnetized at a mechanical angle of 90degrees. As shown in FIG. 3, the radially aligned bonded magnet has theproperties that rise and fall of surface magnetic flux density intransition region A is sudden, peak P1 in the vicinity of rise and peakP2 in the vicinity of fall appear, and there is valley V1 in the center(in mechanical angle, π/4) of region B. As shown in FIG. 7, this isthought to be the effect of the largest opposite magnetic field in thecenter of region B due to finite distribution of the magnetic load(magnetization) appearing on the surface of the anisotropic bondedmagnet.

Incidentally, in the case of the semi-radial alignment of the presentinvention, in transition region A the rise and fall of surface magneticflux density is smooth in comparison to the case of a radiallymagnetized bonded magnet, peaks S1 in the vicinity of rise and S2 in thevicinity of fall are small in comparison the case of radial alignment,and valley U1 in the center (in mechanical angle, π/4) of region B. islarge in comparison to the case of radial alignment. That is, it isunderstood that the difference between a peak and valley (S1-U1) in thecase of the semi-radial alignment of the present invention is smallerthan the difference between a peak and a valley (P1-V1) in the case ofradial alignment. Also, when defining ripple rate as the ratio of thedifference in peak and valley to the average value B_(mav) of surfacemagnetic flux density shown in FIG. 3 in the range of mechanical angleπ/2, ripple rate is 27% in the case of radial alignment, and 11% in thecase of the semi-radial alignment of the present embodiment. In the caseof alignment applying the method devised as a developed form of axialalignment in a 2-axis motor to a 4-pole motor, ripple rate is 10.4%.

The average value B_(mav) of surface magnetic flux density is, whenmaking that value 100 in the case of radial alignment, 103 in the caseof the semi-radial alignment of the present embodiment. In the case ofthe method proposed as a developed form of axial alignment in 2-polemotors applied to 4-pole motors, that average value is 95. When theripple rate is large, because the rise and fall in properties is sudden,cogging torque increases. It is desirable to make ripple rate less than20% as the range in which cogging torque decreases.

On the other hand, the surface magnetic flux density of the anisotropicbonded magnet according to patent documents 2 and 3 in the normalizeddirection after magnetization has the properties shown by curve E inFIG. 3. Because, as explained in the section on the conventionaltechnology, a sufficient aligning magnetic field is not provided,because the anisotropic magnet powder is not aligned in transitionregion A, the magnetization vectors are small even after magnetizing,thought to be caused by low surface magnetic flux density in transitionregion A.

This sort of property in which two peaks appear in the range ofmechanical angle π/2 is thought to be an effect of the opposite magneticfield due to the magnetic load (magnetization) appearing on the surfaceof the anisotropic bonded magnet. In the case where magnetic load(magnetization) is uniformly distributed in the finite range ofmechanical angle π/2, because due to the symmetry of the magnetic load(magnetization) the effect of the opposite magnetic field is greatest inthe center of the region of mechanical angle π/2, as shown in FIG. 7,magnetic flux density is smallest in that center. In the case of thesemi-radial alignment of the present embodiment, because in transitionregion A the alignment direction of the anisotropic rare-earth magnetpowder gradually faces the direction tangential to the periphery as itturns toward the neutral point M, the magnetic load (magnetization)density appearing on the surface of the bonded magnet gradually growssmaller as the alignment direction faces neutral point M. A result ofthis is that as shown in FIG. 7, it is thought that in comparison toradial alignment, with the semi-radial alignment of the presentinvention, the opposing magnetic field is small at the extremity and thecenter of the region of mechanical angle π/2, the peak of bothextremities is smaller, and the valley in the center is larger,resulting in a smaller difference the peak and the valley.

Next, an explanation is made of the above bonded magnet orientationbased on an embodiment executed when press molding. Below, the bondedmagnet produced by this embodiment in referred to as Type A. FIG. 4 is aplane cross sectional diagram of the apparatus, and FIG. 5 is a verticalcross sectional diagram of the apparatus. FIG. 6 is a detailed crosssectional diagram of the part of die 30 including cavity 35. Incylindrical die 30, core 32 with outer diameter 26 mm and comprised of asoft magnetic body is disposed in the center, and cylindrical No. 1 ring34 with inner diameter 26 mm, outer diameter 30 mm, and thickness 2 mm,comprised of magnetic super-hard material which is a ferromagnetic body,is disposed around the periphery of that core 32. Also provided is acylindrical No. 2 ring with inner diameter 33 mm, outer diameter 37 mm,and thickness 2 mm, comprised of magnetic super-hard material which is aferromagnetic body, forming a fixed gap with No. 1 ring 34. Thethickness of No. 2 ring 36 is 2 mm, and saturated magnetic flux densityis 0.3 T. Between No. 1 ring 34 and No. 2 ring 36, cavity 35 withthickness 1.5 mm is formed for the purpose of resin molding. Bondedmagnet raw material constituting magnet powder and resin powder isprovided in this cavity 35.

On the outside of No. 2 ring 36 are provided No. 1 dice 38 a, 38 b, 38c, and 38 d, comprising fan-shaped ferromagnetic bodies divided intoquarters, and No. 2 dice 40 a, 40 b, 40 c, and 40 d provided between theNo. 1 dice, comprising fan shaped non-magnetic bodies such as stainlesssteel. Die 30 is formed by these members. The arc length in across-section perpendicular to the axis of the joined surfaces of No. 2ring 36 and No. 1 dice 38 a, 38 b, 38 c, and 38 d, comprising fan-shapedferromagnetic bodies divided into quarters, is about 23 mm. The arclength in a cross-section perpendicular to the axis of the joinedsurfaces of No. 1 ring 34 and No. 2 dice 40 a, 40 b, 40 c, and 40 d,comprising fan-shaped non-magnetic bodies divided into quarters, isabout 6 mm.

On the outside of die 30 is provided circular pole piece 42, and thatpole piece 42 has 4 divisions 43 a, 43 b, 43 c, and 43 d. Spaces 44 a 44b, 44 c, and 44 d are formed in order to wind a coil between eachdivision. In the space between adjoining coils, for example in spaces 44a and 44 b, coil 46 a is wound such that it includes division 43 abetween those spaces.

In the above structure, it is possible to generate magnetic flux suchthat the surface of pole piece 43 a becomes an N pole by impartingelectric current to coil 46 a, to generate magnetic flux such that thesurface of pole piece 43 b becomes an S pole by imparting electriccurrent to coil 46 b, to generate magnetic flux such that the surface ofpole piece 43 c becomes an N pole by imparting electric current to coil46 c, and to generate magnetic flux such that the surface of pole piece43 d becomes an S pole by imparting electric current to coil 46 d.

Pole piece 42, the four No 1. dice 38, No. 2 ring 36, No. 1 ring 34, andcore 32 are parts with extremely small magnetic resistance in themagnetic circuit, so the orienting magnetic field flows converging onthose parts. The magnetic transparency of No. 1 dice 38 is far largerthan that of No. 2 dice 40. Therefore, the orienting magnetic field isformed as shown in FIG. 6. As shown in FIG. 8, the magnetic fieldcomponent in the normalized direction for cavity 35 is shown by Br andthe magnetic field component in the direction tangential to theperiphery is shown by Bθ. Because No. 2 ring 36 which is a magnetic bodyis provided at this time, part of the aligning magnetic field is inducedalong No. 2 ring 36, goes around into the No. 2 dice which arenon-magnetic bodies, and part of this magnetic flux leaks into cavity35. That is, in cavity 35, aligning magnetic field Bθ in the directiontangential to the periphery is formed in transition region A. The resultof this is that it is possible to obtain a 4-pole bonded magnet with analignment distribution in which, in the transition region in which thedirection of the magnetic poles change, the alignment direction of theanisotropic rare-earth magnet powder points in a direction tangential tothe periphery of the cylindrical side at locations gradually closer tothe neutral point of the magnetic poles, and points in a directiontangential to the periphery at that neutral point, and points in thenormalized direction of the cylindrical side at locations graduallyfurther from the neutral point. Also, absolute value B of the aligningmagnetic field has the properties shown by curve W in FIG. 9. Intransition region A, it is understood that an aligning magnetic fieldgreater than 0.5 T is obtained. On the other hand, as disclosed inpatent documents 2 and 3, in the case of making the No. 2 ring 36 ofnon-magnetic material, absolute value B of the magnetic field inside thecavity has the properties shown by curve W2 in FIG. 9. Absolute value Bof the magnetic field in transition region A clearly decreases incomparison to the case of the present invention, and it is understoodthat the 0.5 T necessary for alignment of the anisotropic rare-earthbonded magnet is not obtained. Particularly, at measurement point R4shown in FIG. 8, 0.5 T is obtained. In the case of radial alignmentobtained by applying a magnetic field from both sides in the axialdirection, as shown by curve W3 in FIG. 9, it is understood that a fixedaligning magnetic field B is obtained across all regions.

In the above structure, the angle which is made the center of axis 11 ofarc-shaped No. 2 dice 40 a, 40 b, 40 c, and 40 d, the region of about22.5 degrees, corresponds to transition region A of FIG. 1. The anglewhich is made the center of axis 11 of No. 2 dice 40 a, 40 b, 40 c, and40 d, the region of about 67.5 degrees, corresponds to transition regionB of FIG. 1. It is possible by this structure to obtain alignment of theanisotropic rare-earth magnet powder as shown in FIG. 1. If a bondedmagnet aligned in this manner is magnetized, it is possible to obtain asurface magnetic flux density distribution in the normalized directionas shown in FIG. 2.

Anisotropic rare-earth bonded magnet 10 is also called a plastic magnet,and representatively, is formed by mixing Nd—Fe—B magnet powder withresin material. Mass production of this magnet has finally been madepossible in recent years by the present applicants. For example, thisanisotropic rare-earth bonded magnet 10 is produced by the productionmethod according to Japanese Unexamined Patent Application (Kokai)p2001-76917A, Registration Number 2816668. This anisotropic rare-earthbonded magnet has a maximum energy product of 10 MGOe to 28 MGOe and canbe produced at present.

Otherwise, ingredients for the anisotropic rare-earth bonded magnet, maybe, other than Nd—Fe—B, Nd—Fe—B related material, for example materialincluding Nd and a rare-earth element other than Nd, or materialincluding other additional elements. Further, material includingrare-earth elements other than Nd, for example Sm—Fe—N material or SmComaterial, or mixtures of these, may be used. This magnet ischaracterized in that maximum energy product (BH_(max)) is more thanfour times greater than that of conventional sintered ferrite magnets.That is, while standard sintered ferrite magnet 23 has a maximum energyproduct (BHmax) fo 3.5 MGOe, the anisotropic rare-earth bonded magnethas a maximum energy product of more than 14 MGOe, which is more thanfour times greater than that of the conventional sintered ferritemagnet. This means that if motor torque is made the same as in theconventional technology (equivalent torque condition), the thickness ofthe permanent magnet can be reduced to about one-fourth.

A publicly known unit diameter may be used for the magnet powder. Forexample, about 1 um average unit diameter in ferrite powder, and 1 to250 um in rare-earth powder. Publicly known material may be used for theresin. Polyamide synthetic resin such as nylon 12 and nylon 6,independent or copolymer vinyl synthetic resin such as polyvinylchloride, those vinyl acetate copolymers, MMA, PS, PPS, PE, and PP,thermoplastic resin such as urethane, silicone, polycarbonate, PBT, PET,PEEK, CPE, Hypalon, neoprene, SBR, and NBR, or thermosetting resin suchas phenol or epoxy resin can be used. It is possible to use a publiclyknown mixture ratio of the magnet powder and synthetic resin. Forexample, it is possible to make that mixture ratio 40 to 90 volumepercent. Also, it is possible to use plasticizers, antioxidants, surfacetreatment agents and the like according to one's purpose.

It is possible to apply the following conditions as productionconditions. Heat-hardening resin was used in the embodiment, butthermoplastic resin may also be used. Press molding was used in theembodiment, but other publicly known production methods may be used.Because press molding and magnetic field alignment were performedsimultaneously in the embodiment, magnetic field heated press moldingwas used. First, molding conditions were made to be die 120 deg. C.,molding pressure 3.0 T/cm2, molding time 15 sec., aligning magneticfield in the main region of the polar period was 0.80 T, and aligningmagnetic field in transition region A in which the direction of themagnetic poles changes was 0.70 T (value at measurement point R4 in FIG.8). Measurement of the aligning magnetic field in transition region Awas at the location shown in FIG. 8. The center line in the peripheraldirection of cavity 35 is L1, the center line of No. 2 dice 40 a is L3,and the normalization line at point R3 of the angle of No. 2 dice 40 ais L2. The intersection of normalization line L2 and center line L1 isR3, and the intersection of normalization line L3 and center line L1 isR1. The magnetic field at center point R4 of points R1 and R3 on centerline L1 was measured with a hall element. The angle position of centerpoint R4 corresponds to the location of 39.375 degrees in the propertiesof FIG. 9, and 84.375 degrees in the properties of FIG. 2.

Next, an anisotropic bonded magnet was molded with No. 2 ring 36thickness of 2 m, saturated magnetic flux density 1.6 T, and cavity 35width of 1.5 mm. Below, this bonded magnet is referred to as type B. Inthis case, the aligning magnetic field at point R4 of FIG. 8 was 0.8 T.

The method of alignment is as stated above. Magnetization was performedas follows. A soft magnetic core on the inside of the cylindrical bondedmagnet and a soft magnetic yoke were disposed as a magnetizing yoke. Themagnetizing magnetic field was the same as the aligning magnetic field,used as a magnetic field parallel to the direction perpendicular to thecylindrical bonded magnet. A pulse magnetic field was employed as themagnetization method, and the magnetizing magnetic field was about 4 T.

Next, with respect to the type A bonded magnet, two types ofsemi-radially aligned anisotropic rare-earth bonded magnets were made,one with magnet BH_(max) of 22 MGOe and coercivity of 14 kOe, and onewith BH_(max) of 21 MGOe and coercivity of 17 kOe.

As a comparison example, when making the No. 2 ring 36 thickness 2 m,saturated magnetic flux density 0.30 T, and cavity 35 width 1.5 mm, thealigning magnetic field at point R4 of FIG. 8 was reduced to 0.45 T. Inother words, even when the No. 2 ring 36 is formed from a magnetic body,when the thickness of No. 2 ring 36 is reduced, it is understood thatthe magnetic field in transition region A of cavity 35 is small.

Likewise, a conventional example of a bonded magnet was made with No. 2ring 36 being a non-magnetic body. The thickness of the non-magneticring corresponding to No. 2 ring 36 was 2 m, saturated magnetic fluxdensity 0T, and cavity 35 width 1.5 mm, in which case the aligningmagnetic field at point R4 of FIG. 8 was 0.48 T. In the case of radialalignment by applying a magnetic field from the axial direction when thethickness of the non-magnetic ring corresponding to No. 2 ring 36 was 2m, saturated magnetic flux density was 0 T, and cavity 35 width was 1.5mm, the aligning magnetic field at point R4 of FIG. 8 was 0.80 T. Thesize of the applied magnetic field was determined such that the magneticfield of cavity 35 in region B in which torque is mainly generated wouldbe 0.80 T.

The type A bonded magnet and radially aligned bonded magnet wererespectively made exciting magnets and DC brush motors were produced.Dimensions of the DC brush motors were all made the same. The outputtorque and cogging torque of these motors was respectively measured.When making the output torque and cogging torque of the DC brush motorusing the radially aligned bonded magnet 100%, the DC brush motor usingthe bonded magnet with the semi-radial alignment of the presentembodiment had output torque of 99.6%, and cogging torque of 52.0%.

In the motor using the bonded magnet with the semi-radial alignment ofthe present embodiment, relative to the motor using a radially alignedmagnet, output torque at 99.6% did not decrease, while there was a greatreduction in cogging torque at 52.0%. That is, it was possible to obtainthe same output torque while reducing only cogging torque to 52.0%. Thusthis is a greatly effective improvement in motor properties, preservinghigh output torque while reducing cogging torque.

The dimensions and properties of the 4-pole DC brush motor using the4-pole anisotropic rare-earth bonded magnet made according to type A ofthe present embodiment are shown along with a radially alignedconventional example in Chart 1. The size of the magnet is internaldiameter 30 mm, external diameter 33 mm, thickness 1.5 mm, and length 30mm. The bake yoke has internal diameter 33 mm, external diameter 37 mm,thickness 2 mm, and length 37 mm. The back yoke material is SPCC, thearmature material is silicon steel plate, the coil winding is adistribution coil, rated electric current 4.6 A.

[Chart 1]

The relationship between torque and revolutions of the motor using thebonded magnet of the present invention is shown in FIG. 10 along withthe properties of a motor using the radially aligned bonded magnet ofthe conventional example. It is understood that the motor using thesemi-radially aligned anisotropic rare-earth bonded magnet of thepresent embodiment does not have properties inferior to the motor usingthe radially aligned bonded magnet.

Because anisotropic rare-earth bonded magnet 10 is made by resinmolding, a hollow cylindrical shape with good precision is formed.Anisotropic bonded magnet 10 is easily precisely symmetricallymagnetized. A magnetic field is precisely symmetrically generated insidethe motor apparatus.

In the above embodiment, range B with a mechanical angle of about 37π/8is made the mechanical angle region in which torque is mainly generated,and range A with a mechanical angle of about π/8 is made the transitionregion in which the direction of the magnetic poles changes. However,the transition region has a range of about a 30 degree mechanical angle,and it is possible to use a range of about 15 degrees. Then the rangewhich mainly generates torque will be the remaining angular region.

The anisotropic bonded magnet of the present invention, produced by theprocessing apparatus of the present invention, can be used as anexciting magnet in a DC brush motor. In this case, it can be used inboth the stator and the rotor, and besides DC brush motors, it can alsobe used in brushless motors, synchronous motors, and the like.

INDUSTRIAL APPLICABILITY

The 4-pole anisotropic rare-earth bonded magnet according to the presentinvention, and the 4-pole anisotropic rare-earth bonded magnet producedby using the alignment process apparatus according to the presentinvention, can be used in a motor which reduces cogging torque withoutreducing output capacity. TABLE MGOe 22 22 21 21 Maximum Energy ProductKOe Coercivity iHc 14 14 17 17 Alignment Method Radial Semi-radialRadial Semi-radial Number of Magnetic Poles 4 Magnet Size Diameter (mm)φ33-φ30 Thickness (mm) 1.5 Length (mm) 30 Back Yoke Diameter (mm)φ37-φ33 Thickness (mm) 2 Length (mm) 37 (Flux Ring Height) ArmatureCoating (mm) 29.6 Torque Constant (mN · m/A) 32.5 32.3 30.1 30.3 MotorVolume (cm³) 50 Motor Weight (g) 280 Performance Index T (mN · m/A ·cm³) 0.65 0.65 0.60 0.61 Magnet Rotation Diameter (mm) φ29 Number ofSlots 10

1.-9. (canceled)
 10. A 4-pole motor anisotropic bonded magnetcharacterized in that the said magnet has a hollow cylindrical shape anda maximum energy product greater than 14 MGOe, formed by moldinganisotropic rare-earth magnet powder with resin, wherein the alignmentdistribution of the anisotropic rare-earth magnet powder in a crosssection perpendicular to the axis of the anisotropic bonded magnet is inthe normalized direction of the cylindrical side of the hollowcylindrical shape in the main region of a polar period, and in atransition region in which the direction of the magnetic pole changes,steadily points towards a direction tangential to the periphery of thecylindrical side at points closer to the neutral point of the magneticpole, and becomes a direction tangential to the periphery of thecylindrical side at that neutral point, and steadily points toward thenormalized direction of the cylindrical side at points farther away fromthe neutral point, and wherein the 4-pole motor anisotropic bondedmagnet in which the said alignment distribution is obtained ismagnetized in an alignment direction.
 11. The 4-pole motor anisotropicbonded magnet according to claim 10, characterized in that orientationof the anisotropic rare-earth magnet powder between transition regionsis performed with an aligning magnetic field of greater that 0.5 T. 12.The 4-pole motor anisotropic bonded magnet according to claim 10,characterized in that, for the surface magnetic flux densitydistribution in the normalized direction of the main polar period aftermagnetization of the anisotropic bonded magnet, the ratio of thedifference between the maximum value and minimum value to the averagevalue in this main region is 0.2 or less.
 13. The 4-pole motoranisotropic bonded magnet according to claim 11, characterized in that,for the surface magnetic flux density distribution in the normalizeddirection of the main polar period after magnetization of theanisotropic bonded magnet, the ratio of the difference between themaximum value and minimum value to the average value in this main regionis 0.2 or less.
 14. A motor having the 4-pole motor anisotropic bondedmagnet according to claim
 10. 15. A motor having the 4-pole motoranisotropic bonded magnet according to claim
 11. 16. A motor having the4-pole motor anisotropic bonded magnet according to claim
 12. 17. Amotor having the 4-pole motor anisotropic bonded magnet according toclaim
 13. 18. An alignment process apparatus for manufacturing, bymolding using a die, a hollow cylindrical-shaped anisotropic bondedmagnet for use in a 4-pole motor, the magnet being formed by moldinganisotropic rare-earth magnet powder with resin, wherein the alignmentprocess apparatus comprises: a core comprising a column-shaped magneticbody provided in a die molding space; a cavity of width 0.7 to 3 mm forfilling with the anisotropic bonded magnet raw material and molding themagnet, the cavity being formed in a cylindrical shape on the outerperiphery of the core; No. 1 one dice, comprising of a magnetic bodydivided into quarters forming an aligning magnetic field in thenormalized direction of the cavity, disposed on the outer periphery ofthe core and facing the center of the core; No. 2 two dice divided intoquarters, comprising a non-magnetic body disposed on the outer peripheryof the core and facing the center of the core, and, corresponding to thetransition region in which the direction of the magnetic poles of thebonded magnet changes, located between the adjacent No. 1 dice; coilsconferring magnetic flux on the four No. 1 dice; and a magnetic fluxinduction member comprising a thin-walled cylindrical magnetic bodywhich forms the outer peripheral surface of the cavity.
 19. Thealignment process apparatus according to claim 9, characterized in thatthe thickness of the magnetic flux inducement member is 1.0 to 3.5 mm.20. The alignment process apparatus according to claim 9, characterizedin that the magnetic flux inducement member is comprised of super-hardmaterial.
 21. The alignment process apparatus according to claim 10,characterized in that the magnetic flux inducement member is comprisedof super-hard material.
 22. The alignment process apparatus according toclaim 9, characterized in that the aligning magnetic field of the regionof the cavity in which the No. 2 dice are present induces magnetic fluxgreater than 0.5 T.
 23. The alignment process apparatus according toclaim 10, characterized in that the aligning magnetic field of theregion of the cavity in which the No. 2 dice are present inducesmagnetic flux greater than 0.5 T.
 24. The alignment process apparatusaccording to claim 11, characterized in that the aligning magnetic fieldof the region of the cavity in which the No. 2 dice are present inducesmagnetic flux greater than 0.5 T.
 25. The alignment process apparatusaccording to claim 12, characterized in that the aligning magnetic fieldof the region of the cavity in which the No. 2 dice are present inducesmagnetic flux greater than 0.5 T.
 26. The alignment process apparatusaccording to claim 9, characterized in that it possesses a ringcomprising cylindrical thin-wall magnetic super-hard material whichforms the inner surface of the cavity, disposed on the outer peripheryof the core.
 27. The alignment process apparatus according to claim 10,characterized in that it possesses a ring comprising cylindricalthin-wall magnetic super-hard material which forms the inner surface ofthe cavity, disposed on the outer periphery of the core.
 28. Thealignment process apparatus according to claim 11, characterized in thatit possesses a ring comprising cylindrical thin-wall magnetic super-hardmaterial which forms the inner surface of the cavity, disposed on theouter periphery of the core.
 29. The alignment process apparatusaccording to claim 12, characterized in that it possesses a ringcomprising cylindrical thin-wall magnetic super-hard material whichforms the inner surface of the cavity, disposed on the outer peripheryof the core.
 30. The alignment process apparatus according to claim 13,characterized in that it possesses a ring comprising cylindricalthin-wall magnetic super-hard material which forms the inner surface ofthe cavity, disposed on the outer periphery of the core.
 31. Thealignment process apparatus according to claim 14, characterized in thatit possesses a ring comprising cylindrical thin-wall magnetic super-hardmaterial which forms the inner surface of the cavity, disposed on theouter periphery of the core.
 32. The alignment process apparatusaccording to claim 15, characterized in that it possesses a ringcomprising cylindrical thin-wall magnetic super-hard material whichforms the inner surface of the cavity, disposed on the outer peripheryof the core.
 33. The alignment process apparatus according to claim 16,characterized in that it possesses a ring comprising cylindricalthin-wall magnetic super-hard material which forms the inner surface ofthe cavity, disposed on the outer periphery of the core.